Methods and apparatus for additively manufacturing a structure with in-situ reinforcement

Abstract

A method of additive manufacturing is provided. The method of additive manufacturing includes depositing a layer of base material from which an additively manufactured part is produced. The method also includes dissolving a resin in a solvent to form a resin solution, and depositing the resin solution upon the layer of base material.

What is claimed is: 
     
       1. A method of additive manufacturing, the method comprising:
 depositing a layer of base material from which an additively manufactured part is produced; 
 dissolving a resin in a solvent to form a resin solution; and 
 depositing the resin solution upon the layer of base material to form a distinct sheet that is disposed on and planarizes a surface of the base material. 
 
     
     
       2. The method of  claim 1 , wherein the resin is a thermoplastic resin. 
     
     
       3. The method of  claim 1 , further comprising depositing another layer of base material on top of the layer of base material upon which the resin solution has been deposited. 
     
     
       4. The method of  claim 3 , wherein the distinct sheet of resin solution forms an interstitial sheet that is disposed between and couples adjacent layers of the base material to each other where the interstitial sheet at least partially fills one or more of voids and pores of each of the layer of base material and the other layer of base material. 
     
     
       5. The method of  claim 1 , wherein depositing the layer of base material includes depositing a plurality of filaments of base material in a side-by-side arrangement so as to form the layer of base material, where
 the layer of base material includes one or more of voids and pores, and 
 depositing the resin solution upon the layer of base material at least partially fills the one or more of voids and pores. 
 
     
     
       6. The method of  claim 1 , wherein depositing the layer of base material includes depositing a powdered base material so as to form the layer of base material, where
 the layer of base material includes one or more of voids and pores, and 
 depositing the resin solution upon the layer of base material at least partially fills the one or more of voids and pores. 
 
     
     
       7. The method of  claim 1 , wherein depositing the resin solution upon the layer of base material includes spraying, with a deposition device, the resin solution upon the layer of base material, where the deposition device is movable. 
     
     
       8. The method of  claim 7 , further comprising positioning the deposition device relative to the layer of base material with a computer controlled positioning mechanism. 
     
     
       9. The method of  claim 1 , wherein depositing the resin solution upon the layer of base material includes spraying the resin solution upon the layer of base material with a deposition device that is fixed relative to the layer of base material. 
     
     
       10. The method of  claim 1 , wherein the resin solution includes a reinforcing agent. 
     
     
       11. An additively manufactured part comprising:
 at least one layer of base material; and 
 a reinforcing agent disposed on the at least one layer of base material, where the reinforcing agent is deposited upon the at least one layer of base material as a resin solution, the resin solution with the reinforcing agent therein forms a distinct sheet disposed between adjacent layers of the at least one layer of base material and at least partially fills one or more of voids and pores in each of the adjacent layers of the at least one layer of base material, wherein the distinct sheet of resin solution effects coupling of the adjacent layers of the at least one layer of base material so that the additively manufactured part exhibits substantially isotropic mechanical strength. 
 
     
     
       12. The additively manufactured part of  claim 11 , wherein the resin solution includes a thermoplastic resin. 
     
     
       13. The additively manufactured part of  claim 11 , wherein the reinforcing agent is interstitially disposed between the adjacent layers of base material, at least partially filling the one or more of voids and pores, so as to reinforce coupling of the adjacent layers of base material. 
     
     
       14. The additively manufactured part of  claim 11 , wherein the at least one layer of base material includes a polymer. 
     
     
       15. The additively manufactured part of  claim 11 , wherein the at least one layer of base material includes a metal. 
     
     
       16. An additive manufacturing apparatus comprising:
 a frame; 
 a base material support bed coupled to the frame; 
 a base material deposition unit movably coupled to the frame and being disposed above the base material support bed, the base material deposition unit being configured to deposit one or more layers of base material upon the base material support bed; and 
 a spray deposition device coupled to the frame so as to be positioned relative to the frame and being configured so as to deposit a resin solution upon the one or more layers of base material, in situ with the deposition of the one or more layer of base material, where the spray deposition device comprises a spray nozzle that is configured to deposit a resin solution that forms a distinct interstitial layer between adjacent layers of base material where the interstitial layer has a thickness that fills one or more of voids and pores of each of the adjacent layers. 
 
     
     
       17. The additive manufacturing apparatus of  claim 16 , wherein the frame forms a chamber that encloses at least the spray nozzle of the deposition device, where the resin solution exits the deposition device through the spray nozzle. 
     
     
       18. The additive manufacturing apparatus of  claim 16 , further comprising a controller configured to control positioning movement of one or more of the base material deposition unit and the deposition device. 
     
     
       19. The additive manufacturing apparatus of  claim 16 , further comprising a heater configured to heat the resin solution deposited upon the layer of base material so as to reduce an amount of solvent in the resin solution. 
     
     
       20. The additive manufacturing apparatus of  claim 16 , further comprising a reservoir configured to store the resin solution and being coupled to the deposition device so as to supply the resin solution to the deposition device.